Success Stories

SUCCESS STORIES

As one of Europe’s oldest manufacturers of screening and separation equipment (dating back to 1946) Virto has recorded thousands of case studies detailing how its industrial screening solution has performed for certain materials or industries at various cut points and capacity requirements.

Virto has commenced the process of creating a searchable online case study library. If you cannot find a case study for your material and requirements, there is a good chance our comprehensive library will provide the information you need.

Take a look at our case studies and feel free to contact us with questions.

Replaced Equipment: Competitor sieve technology that yielded lower efficiency and could not screen at fine apertures;

Type of Screening Mesh: Nylon mesh with 11 micron cut point;

Key Objectives: Screen Aluminium Powder below 11 µm to be used for the additives manufacturing industry;

Results needed: High purity level with particles separation at the required cut point, offering greater flow-ability to the powder;

Main Challenges: Due to its explosive characteristics, the screening of aluminium powder below 45 µm can be dangerous. Furthermore, at a fine cut point the powder blinds the mesh on standard screening equipment.

Competitor Product considered: Air classification was considered but the efficiency of the system was not effective for their end users due to excessive contamination.

Results achieved: The X-Line CS 120.1 achieved a throughout of 70 kg/hour at 11 µm with efficiency of 98%.

Screened Product: Classification of aluminium powder at two different cut points;

Mesh: Nylon mesh with 2 x cut points at 45 µm and 6 µm;

Key Objectives: Screen aluminium powder below 25 µm to be used for the additives manufacturing industry;

Main Challenges: Due to its explosive characteristics the screening of aluminium powder below 45 µm can be dangerous. Furthermore, at a fine cut point the powder blinds the mesh on standard screening equipment.

Competitor Product considered: Air classification was considered but the efficiency of the system was not effective for their end users due to excessive contamination.

Results Achieved: The X-Line CS 120.1 achieved a throughout of 400 kg/hour at 45 µm and 71 kg/hour at 6 µm with efficiency of 98%

Project: Grading of Cenospheres for the production of thermal insulation coating;

Client: Large coatings manufacturer;

Type of Screener: Virto’s T-Line Tumbler was able to screen at up-to six simultaneous separations, is a high capacity machine used for dry powders. The model used for this material was the VTU 2000 (2 meter diameter) with three decks and silicon balls mesh cleaning system on each of the decks;

Main Challenges: Increasing level of purity of oversize and of undersize without reducing capacity;

Competitors Product considered: With the existing equipment the client experienced frequent problems of sieve blinding, oversize contamination by undersize fraction up to 10% and undersize contamination by oversize fraction up to 35%;

Results Achieved: Virto Group's rectangular X-LINE was able to remove all of the fine powder undersize below 1.25 mm and achieved a high capacity of 30 T/Hour within a 24/7 operation which exceeded the customers requirements. Efficiency: 98%-99% and no mesh blinding.

Type of Screener: Virto designed the solution to deslime coal fines dredged from waste dumps at 100 micron on two multi-frequency X-Line RS 2010 machines. Once the slurry is deslimed the ash content is further reduced by using a bank of triple start Multotek spirals. The recovered product is then dried using four RS 2010 dewatering vibrating sieves resulting in an average of 15% moisture in the final product. The solution is designed to recover up to 20 tons per hour of fine coal and utilizes six of Virto's X-Line RS 2010 multi frequency screens.

Mesh: For scalping - Stainless steel mesh with an opening of 3 mm. For Desliming - Polyurethane mesh with an opening of 100 micron. For dewatering - Nylon mesh with opening of 250 micron;

Key Objectives: To recover and produce, from the slurry waste, a marketable product that meets the specifications of the client. In this case the client needed a reduction of the Ash content in the waste from c. 35% to less than 16% at a maximum yield;

Main challenges: It was previously impossible to screen the product and get the required reduction in Ash content at less than 300 microns.

Results achieved: The X-Line machines achieved the required efficiency in Ash reduction at 100 micron, increased the yield and increased capacity. The plant is currently running at a recovery rate of 8-10 tons per hour and consistently produces -16 Ash material at 15% moisture.

Key Objectives: Client required the classification of Copper Powder to attain various grades at 40µ and 15µ. This level of fine screening had not been possible by other screening equipment manufacturers as the client explained;

Main Challenges: If this Copper Powder could be screened was the major question, especially at such fine particle sizes. Could the X-LINE multifrequency technology overcome electrostatic build-up, which causes the mesh to blind;

Competitor product considered: This client had been searching for a screening solution for many years. They tried ultrasonic technology by two major supplierss but were not succesful in achieving fine screening;

Results Achieved: X-LINE was able to easily screen at 40µ and offered extremely positive results on 15µ mesh, reaching a screening capacity of 35 Kg/hour on this difficult material.

Replaced equipment: Rotary/centrifugal screener this technology was not offering the desired capacity and was extremely difficult to clean for product change-over

Mesh: Nylon mesh with apertures of 100, 250, 335 and 500 micron

Key Objectives: The end user turned to Virto Group for increasing their screening capacity, reduction in waste product, greater screening efficiency and most importantly to have a machine which is easy to clean and allows rapid product change over

Main Challenges: The X-Line was able to overcome the binding forces of high fat content in the powder and yet offer higher capacities than the clients current equipment

Competitors: The client tried standard industrial sieves but the screening efficiency and capacity were both unacceptable

Results Achieved: Ranging from 120 Kg/H to 480 Kg/H, X-Line technology is able to screen these sticky, agglomerative and difficult to sieve powders. We offer an easy to clean, crevice free equipment designed to serve the cosmetic industry for high capacity and efficient screening.

Reason for Substituting Existing Equipment: the existing screening equipment was only able to operate with a rectangular 2.5 x 8 mm mesh. The humid crushed dolomite is all less than 6 mm in size and has high tendency to agglomerate and blind the mesh.

Key Objectives: De-dust the product at a very high throughput and remove the undersize at a 5 mm cut point.

Main Challenges: To overcome mesh pegging from particles that are similar in size to the mesh aperture whist over-powering the natural humidity of the crushed limestone (up to 6%) that causes agglomeration and makes the material sticky.

Results achieved: Using 2 x RS2310.1 machines, the rectangular X-Line was able to remove all of the fine powder below the 5 mm aperture and achieve 100 Tonnes/Hour throughput on 24 x 7 operations.

Type of Screener: Virto C-Line VP2 1500, single deck vibrating sieve with a straight through design, two motors mounted one on either side, quick release band clamp and silicon balls as a mesh cleaning system;

Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding;

Main Challenges: increase screening efficiency whilst maintaining same capacity; reducing plant space occupied by the screening line whilst maintaining the same capacity and guaranteeing continuous feeding of the furnace;

Competitor Product Considered: several other suppliers were considered but none could guarantee same ability to resolve all problems faced;

Project: Safety screening of Protein powder from rice and beans prior to packaging;

Client: European food ingredient producer;

Type of Screener: Virto C -Line VP2 500 in single deck configuration

Mesh: Stainless steel mesh with a 750 µm aperture;

Key Objectives: Client required the safety-screening of product at a capacity of 150 Kg/Hour whilst incorporating a magnetic separator installed at the outlet of the machine to capture small ferrous particles. The machine had to be as small as possible due to available space constraints;

Main Challenges: Due to the product’s agglomerative, hygroscopic characteristics and its tendency to blind the mesh, it was a challenge to achieve the required capacity and to separate powder at maximum efficiency, using a small sieve of 500mm diameter;

Competitor product considered: several suppliers were considered but C-Line VP2 500 provided the best results based on efficiency and capacity;

Results achieved: The smallest model of VP2 equipped with a magnetic separator at the outlet of the machine, achieved the requested capacity of 150 Kg/Hour, fitting perfectly in a low headroom.

Key Objectives: To screen the quartz sand and deliver a final product that was -425 µ and +160 µ. The efficiency needed to be at least 92% with a throughput of 10 Tonnes/Hour.

Main Challenges: To overcome mesh blinding and mesh tearing caused by the irregular shape of the quartz sand particles.

Results Achieved: Virto Group provided 6 x rectangular X-Line machines (RS 2010.1) and achieved a total throughput of 15 Tonnes/Hour with an efficiency in separation of 95% on the 425 µ separation and was extremely effective in de-dusting the product at 160 µ.

Project: Separation of Dry Quartz Sand for use in the production of glass;

Client: European producer of minerals for glass, chemical and building materials;

Type of Screener: Virto’s T-Line Tumbler, that is able to separate 6 grades of powder simultaneously and it is a high capacity machine used for dry powders. The model used for this material was the VTU 2000 (2 meter diameter) with single deck and silicon balls mesh cleaning system;

Type of Screening Mesh: Stainless steel with apertures of 104 µm;

Key Objectives: To allow for high capacity but highly efficient separation at the requested cut point;

Main Challenges: To eliminate mesh blinding caused by the irregular crystalline shape of this material, whilst retaining good mesh life and achieving more than 2 T/Hour throughput;

Key Objectives: The client needed to set up an energy-efficient production process for a new granite product line created from the fines from the crushing process. They needed to achieve efficient separation of the crushed granite at 0 - 0.6 mm, 0.6 - 2.5 mm and 2.5 – 5.0 mm;

Main Challenges: The humidity of the product was up to 5% and this caused mesh blinding problems and low efficiency;

Results Achieved: X-Line was able to achieve what no other screening equipment could deliver. It created a new product line from crushing tails that were previously dumped. The separation efficiency that was achieved ranged from 88% – 94% with feed capacity to the line in the range of 24-28 Tonnes/Hour for a 24/7 operation.

Project: Grading of Fish Food at 790, 606, 436, 209 and 125 micron. The food is graded for the fish farming industry as well as the pet industry

Country: France

Type of Screener: Virto’s VTU Tumbler, designed specifically for light/delicate materials to achieve high capacity with up to 6 separations at the same time. The model of the Tumbler used was the VTU 900, which is 0.9 m diameter

Replaced equipment: New project, no previous processing

Mesh: Stainless steel at various aperture sizes

Key Objectives: To allow for high capacity grading at 6 different cut points while ensuring that the separation is efficient

Main Challenge: To remove agglomerates that are sticky and cover the mesh

Competitors: Only a handful of manufacturers are able to offer multiple layer screening. Virto’s Tumbler was able to achieve higher efficiencies and capacity

Results Achieved: Using the 0.9 m diameter model of the Tumbler, we achieved 514 Kg/Hour capacity with 97% efficiency at each cut point

Key Objectives: Effectively safety screen the product at a capacity of at least 1 Tonne/Hour, offering greater flow-ability to the powder;

Main Challenges: The product is difficult to screen due to its humid nature. This causes mesh blind, consequently reducing the material flow and ultimately blocking the mesh completely;

Results achieved: The VPM 1500 exceeded the required capacity and reached 1,450 Kg/Hour. It allowed the customer to safety screen the product at 1 mm without mesh blinding or the gradual reduction in capacity.

Key Objectives: To create new products for the farming industry. The aim of the screening was to create specific fertilizer from Grape Pomace waste materials. This material offers many benefits to the farming industry due to the presence of a considerable proportion of organic matter, which is easily converted into humus soil. In addition, it is a valuable source of nitrogen, potash, and phosphoric acid. The amounts of these, however, are variable, dependent on the character of the pomace and treatment it has undergone. The amount of water, of course, influences the percentage composition and therefore, the dry form of pomace provides higher percentages of the plant foods than the wet or fresh material. For this reason, it was important to achieve high quality of fertilizer rather than high quantity.

Main Challenges: Particle size of the Grape Pomace was similar to the mesh aperture, the humidity of the product made it sticky and finally, the client was seeking a low cost solution.

Competitors: Several suppliers were considered but only Virto C-Line provided best results, because we decide to do several test in order to check how the product behaves during the sieving process. The first test was done with a single mesh and rubber balls were used as the mesh cleaning system. However, through our extensive experience we noted that two deck configuration without rubber balls mesh-cleaning system would offer desired results. Several further tests were conducted at our dedicated test laboratory to ensure a fully personalized solution was offered to the client and to exceed their expectations.

Results Achieved: The VPB 500 was able to effectively separate different particle size distributions with high precision, exactly what the client was looking for. The cost of this unit is extremely attractive and the client was impressed with the build quality of the machine.

Main Challenges: Due to the low bulk density of Graphite, it is a huge challenge to achieve high capacity screening while using mesh below 100 micron

Competitor Product Considered: several suppliers were considered; however, following a short trial at our Factory in Reggio Emilia, X-Line technology proved to offer the best possible results

Results Achieved: Therefore, the X-Line speed was adjusted accordingly, which produced good capacity and eliminated mesh blinding. Capacity achieved was 785 Kg/hour on 75 micron and 515 Kg/hour on 45 micron mesh apertures. The efficiency of the screening was calculated at 95%.

Project: Topping and tailing of grated Grated Cheese to remove fines and large flakes;

Country: Italy;

Type of Screener: Virto C-Line VPM 1200 single deck with silicon balls for cleaning the mesh. This unit can be supplied with multiple decks and is the most trusted screening solution in the market;

Replaced Equipment: New installation;

Mesh: Stainless steel mesh with 10 mm aperture;

Key Objectives: Client required control screening of Grated Cheese at 10 mm cut point with a capacity of 5,000 Kg/h and an efficiency of 99%;

Main Challenges: To ensure the product does not disintrate during screening while maintaining high capacity;

Competitors: Client met us at Cibus Tech 2014 exhibition and was impressed by our equipment on display. They did not explore any other suppliers;

Results Achieved: Virto C-Line achieved 6,700 Kg/h capacity, while the mesh remained clean and client was able to switch between screen sizes quickly and efficiently, allowing to further save costs of investment and maintenance.

Screened Product: Gypsum used for the manufacture of cement and plaster;

Mesh: Nylon mesh with an aperture of 200 µm;

Key Objectives: Create new product line - very fine, high quality Gypsum;

Main Challenges: To overcome mesh pegging caused by particles that are near sized to the mesh aperture and then wedged which reduced throughput and increased contamination;

Competitor product considered: NA

Results Achieved: Virto Group's rectangular X-LINE was able to remove all of the fine powder undersize below 200 micron and achieve high efficiency in the separation. The X-LINE RS2310 also created a high quality, very fine (0-200 µm) gypsum product as well as achieve a high capacity of 4 t/h which exceeded the customers requirements.

Key Objectives: To remove the contamination at relatively high capacity and avoid mesh blinding;

Main Challenges: Overcome the sticky nature of the product, which has high angle of repose (35-55 degrees) and ensure continues removal of over-size contamination off the screen;

Competitors Product Considered: Virto Group's X-Line RS 2310 was a clear choice, due to its compact design, it is able to operate in low head-room and it has relatively smaller footprint, yet offering higher capacity and efficiency;

Results Achieved: With a mesh surface area of 1.9 m², the X-Line RS 2310 was able to achieve 9 T/h capacity. No mesh blinding occured and the screening efficiency was 99.9%.

Type of Screener: T-Line VTU 2400 Tumbler that offers up to six separations simultaneous, is a high capacity machine used for dry powders. The model used for this material was 2.4 meter in diameter; with single deck and a silicon balls mesh cleaning system;

Mesh: Stainless steel mesh with a 2 mm aperture and cross beam as a support for the mesh to increase its operational life;

Key Objectives: Screening of the product to remove the particles above 15 micron and obtain the highest purity level;

Main Challenges: As this material cannot be screened on standard sieving equipment that are currently available in the market. The yield was far too low on other classification systems as well as low efficiency of separation. The challenge was to mechanically screen the powder and to offer high accuracy of particle size distribution;

Key Objectives: Effectively safety screen the product at a capacity of at least 1,400 Kg/Hr with an opening of 1 mm, offering greater flow-ability to the powder;

Main Challenges: Due to its lightness, the product it’s difficult to screen. Furthermore it has 5% humidity, it’s sticky and hygroscopic;

Results achieved: The VPM 1200 exceeded the required capacity of 1,400 Kg/Hr reaching 2,150 Kg/Hr. It enables the customer to get the safety screening of the protein pea at 1 mm without facing any issue.

Key Objectives: To classify the perlite powder at a 50 µm cut point obtaining two products with high purity level;

Main Challenges: Due to its low bulk density, the product was difficult to screen. Furthermore, the required capacity was a minimum of 500 Kg/Hour obtained with one machine only.

Results achieved: X-Line CS 095 reached the required capacity of 500 Kg/Hour despite the ultrafine cut point and the low bulk density of the product, enabling the customer to get the efficient separation of the perlite. No mesh blinding issues were experienced.

Type of Screener: Virto rectangular screener, X-Line model RS 2310.1 (2 units) and one RS 2010.1 - each with a single deck configuration.

Screened Product: The dolomite product was an animal feed additive that needed to meet strict government guidelines on quantity and size. Therefore, the client needed very efficient separation for the following +2.5 mm was returned to the crusher, 2.5 – 0.80 mm (800 micron) for product 1 and 0.80 – 0.00 mm for product 2.

Key Objectives: Create two new product lines for Virto’s client at these cut points

Main Challenges: To overcome mesh pegging from particles that were similar in size to the mesh aperture and to do so with a high throughput.

Results Achieved: The combination of Virto’s rectangular X-Line machines enabled the client to produce a high quality 0.8 - 2.5 mm product (product 1) which removed nearly all traces of oversize (+2.5 mm) and undersize (less than 0.80 mm) contamination. Similarly, for the 0.80 – 0.00 mm product the government specifications were met. Furthermore, there was only a loss of 1.5% of final product in the +2.5 mm oversize representing a 98.5% efficiency. In terms of capacity, the X-Line RS 2310.1 units achieved 24 TPH throughput and the RS 2010.1 achieved 30 TPH.

Key Objectives: Client required to check-screen the product at a capacity of 900 Kg/Hour whilst also allowing for an effective cleaning and maintenance as well as an easy mesh replacement and changing;

Main Challenges: To achieve the required capacity and to separate powder coating at maximum efficiency;

Competitor product considered: several suppliers were considered but X-Line CS 095.1 provided the best results based on efficiency and capacity;

Results achieved: Thanks to the applied multi-frequency technology, the CS 095.1 achieved more than 900 Kg/Hour throughput at maximum efficiency.

Type of Screener: The Virto T-Line VTU Tumbler with a silicon balls mesh cleaning system. The model used for this material was the VTU 2000 (2.0 metre diameter) with a single deck;

Mesh: Nylon mesh with a 790 µm aperture;

Key Objectives: Client required a cost effective screening solution to classify the product at a capacity of at least 10 Tonnes/Hour whilst also maximising mesh lifetime and minimising production downtime;

Main Challenges: To increase mesh lifetime and achieve maximum efficiency at a throughput of 10 Tonnes/Hour;

Key Objectives: To allow for high capacity but highly efficient grading at three different cut points;

Main Challenges: To achieve maximum efficiency and more than 25 Kg/Hour throughput, bearing in mind this material is extremely difficult to screen at fine apertures. Recycled rubber has the tendency to crystalise and thereby create fines which offer a complete varied morphology to the original material. This varied material properties offer a number of challenges when screening to remove coarse particles as well extremely fine particles;

Results Achieved: The C-Line VPM 900 achieved 180 Kg/Hour throughput with a high separation efficiency. The capacity achieved was well above the client’s requirements, especially as they were only able to gain 20Kg capacity with their existing equipment. Virto’s equipment was able to provide this client with a prospect of business growth using the VPM 900 Separation equipment.

Type of Screener: Virto T-Line Tumbler, that can do up six simultaneous separations, is a high capacity machine used for dry powders. The model used for this material was the VTU 2400 (2.4 metre diameter) with three decks and a silicon balls mesh cleaning system;

Replaced equipment: New line, no previous processing;

Type of Screening Mesh: Stainless steel at 830, 606 and 436 µm;

Results needed: To allow for high capacity but highly efficient grading at three different cut points;

Main Challenges: To achieve maximum efficiency and more than 10 T/hour throughput;

Competitor product considered: The client tried standard industrial sieves but the screening efficiency and capacity were both unacceptable.

Results Achieved: The T-Line Tumbler (2.4 m diameter) achieved more than 14 Tonn/Hour throughput with a high separation efficiency.

Main Challenges: Minimum capacity of 300 Kg/Hour to be achieved with one machine only and to overcome mesh blinding due to the agglomerative nature of the flour;

Results Achieved: The C-Line VPM 1500 double deck achieved the customer’s throughput requirements of 300 Kg/Hour, with an efficiency level of 90% in separation. This efficiency was far higher than the client was previously achieving whilst using competitor equipment of similar specification.

Type of Screener: Virto C -Line VLM 900 1x in single deck configuration, with mesh cleaning system in stainless steel 316 with cylinders and washing system with nozzles installed on the cover. To properly separate the acid slurry, all the gaskets are in Viton, the contact and non-contact parts are in stainless steel AISI 316 and all the internal parts (cover, deck and basement) are coated in polyurethane.

Main Challenges: Due to the acidity of the slurry, it couldn’t be used a standard stainless steel 304 and it was needed something to protect the machine and the internal part from the corrosive acid effect.

Results Achieved: The 100% customized VLM 900 1/X achieved the required capacity of 0,8 M3/H and even overachieving expectations up to 1.5m³/H. It enabled the customer to get the solids/liquid separation of the acid slurry at the requested cut point.

Key Objectives: The aim was to separate the material at two different cut points to obtain two types of silicon with the highest separation efficiency possible and to be used for different application;

Main Challenges: Silicon is a difficult product to screen due to its tendency to blind the mesh causing agglomeration and reduction in screening capacity due to its low bulk density and its sticky nature;

Results achieved: Virto X-Line overcame the mesh blinding problems, achieved the customer's efficiency requirements and the necessary throughput of more than 40 Kg/hour at 200 µm and 20 Kg/Hour at 100 µm.

Key Objectives: Client required the classification of Silver Powder at 50 micron without the irregular shaped particles blinding and pegging the mesh.

Main Challenges: The screening equipment needed to overcome the electrostatic build-up and the irregular shaped particles both of which caused the mesh on standard screening equipment to blind.

Competitor product considered: The client tried many different sieving and separation technology alternatives without obtaining a satisfactory result (including screeners with ultrasonic mesh cleaning systems and air classifiers).

Results Achieved: X-Line screened the powder at 50 micron and obtained a capacity of 24 Kg/hour, the mesh remained completely clear from pegging and blinding.

Screened Product: To screen finest grade of powder to create new product line;

Mesh: Nylon mesh with an aperture of 6 micron;

Key Objectives: Client required the classification of Silver Powder, this level of fine screening had not been possible by other screening equipment manufacturers as the client explained;

Main Challenges: Could this Silver Powder actually be screened, was the major question, especially at such fine particle size. Could the X-Line multifrequency technology overcome electrostatic build-up, which causes the mesh to blind;

Competitor product considered: This client had been searching for a screening solution for a long time. They tried other vibrating sieves but were not successful in achieving fine screening and had to look at alternative methods of classification;

Results Achieved: X-Line was able to screen at 6 micron, reaching a capacity of 15 Kg/H on this impossible to screen material.

Type of Screener: Virto’s specialist safety screener for powders C-Line VP2 2000, single deck vibrating sieve with a straight through design, two motors mounted one on either side. This screener is designed with a quick release band clamp and is offered with a silicon balls mesh cleaning system;

Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding;

Mesh: Nylon mesh with a 2 mm aperture;

Results needed: Client required a cost effective solution to safety-screen their powder at a throughput of 20 Tonnes/Hour;

Main Challenges: Ensuring that there was a minimum amount of undersize product lost with the oversize particles. In addition to this, there was a need for the screening solution to remove electrostatic build-up which caused mesh blinding;

Key Objectives: To produce the metal powder in-house to control quality and to meet their growth plans;

Main Challenges: Overcome mesh blinding and reach a high purity level with high capacity, the particle size distribution to remain within 15µ with an efficiency of separation to be above 93%;

Competitor Product considered: The client tried existing standard sieve manufacturers that used ultrasonic mesh cleaning systems and air classifiers but could not get the desired results. Whereby, the ultrasonic was unable to screen below 45 micron effectively and the efficiency of the air classification system was close to 80%. Both of these alternative solutions were also expensive and did not fully satisfy the clients requirements;

Results Achieved: The X-Line CS 095.2 achieved a throughout of 130 kg/hour at 38 µm and 65 kg/hour at 15 µm with efficiency of 98%. This of course meant the client was able to screen finer with much higher efficiency than previously possible within a cost effective and self-sufficient screening solution.

Key Objectives: To produce the metal powder in-house to control quality and to meet their growth plans.

Main Challenges: Overcome mesh blinding and reach a capacity of 250 Kg/hour.

Competitors: The client tried existing standard sieve manufacturers that used ultrasonic mesh cleaning systems and air classifiers but could not get the desired results.

Results Achieved: Virtos X-Line achieved the customer's efficiency requirements at 22 micron, overcame mesh blinding problems and exceeded the requirements in capacity achieving 353 Kg/h, this enabled the company to become self-sufficient for their powder metal needs.

Type of Screening Mesh: Meshes with different cut points, opening between 40 micron and 1000 micron;

Reason for Substituting Existing Equipment: Increase output volume; produce a higher range of final products (i.e. tantalum powder in different granulometries at set purity levels); improve the quality of the Tantalum production;

Results Needed: Produce a higher range of final products (i.e. Tantalum powder in different granulometries at set purity levels); increase capacity; increase efficiency;

Main Challenges: Increasing level of purity of screened product without reducing capacity;

Competitor Product Considered: Several suppliers were considered but X-Line was giving best results;

Main Challenges: This material is prove to agglomeration and can easily coat the mesh and create a blinding effect. The main challenge was to keep the mesh clean and to ensure and contaminations were automatically removed from the sieve;

Key Objectives: To achieve a high screening throughput of 3 T/Hour with maximum efficiency in the separation;

Results Achieved: The C-Line VP2 2000, specifically designed for the safety screening of powders, offered higher capacity than the desired throughput achieving 3500 Kg/Hour with an efficiency of 99%.

Competitors Product considered: This client had been searching for a screening solution for many years. They tried ultrasonic technology by two major suppliers but were not successful in achieving fine screening;

Results Achieved: Virto X-Line was able to easily screen at 25µ and achieved the customer's efficiency requirements at 15 micron overcoming the mesh blinding problems and exceeded the requirements in capacity achieving 12 Kg/Hour with efficiency of 99%.

Key Objectives: To remove the undersize powder at a 44 µm cut point obtaining a new product with high purity level;

Main Challenges: The client needed to overcome mesh pegging/blinding while trying to screen the material. However, screening titanium powder at a particle size that is less than 50 µm is challenging due to the risk of the dust cloud creating an explosive atmosphere. Therefore, any solution that overcame the mesh blinding also needed to minimize or remove the explosion risk.

Key Objectives: To remove the undersize powder at a 50 µm cut point and increase the throughput and the efficiency of the separation of the existing line;

Main Challenges: The client needed to overcome mesh pegging/blinding while trying to screen the material. However, screening titanium powder at a particle size that is less than 50 µm is a workplace, health and safety challenge due to the risk of the dust cloud creating an explosive atmosphere. Therefore, any solution that overcame the mesh blinding also needed to minimize or remove the explosion risk.

Results achieved: X-Line exceeded the customer's efficiency requirements achieving 99% efficiency with a throughput of 80 Kg/Hour of final product. The mesh cloth was inspected and no pegging could be seen and the explosion risk was mitigated by the use of argon to purge any oxygen within the machine.

Key Objectives: To separate all material above 150 micron with high efficiency, high capacity and with single pass through the X-Line sieve;

Main challenges: Tungsten is an extremely abrasive material, due to this, the mesh can break quickly and often. With most irregular shape metal powders, it is critical to over-come the pegging of the mesh and to ensure the sieve has high percentage of open surface area;

Competitor product considered: This client had been searching for a screening solution for a long time. They tried other vibrating sieves but were not successful in achieving fine screening and had to look at alternative methods of screening their powder;

Results achieved: Virto X-Line achieved all of the core objectives with the use of MFV technology, offering high purity of final product obtained with high level of capacity of 1400 Kg/h.

Type of Screener: Virto advised the client to use a single deck T-Line Tumbler VTU 2000 (2 meter diameter) that is designed specifically for separating low bulk-density materials at a high throughput. The VTU 2000 was supplied with a mesh-cleaning system using silicon balls.

Replaced equipment: New line, no previous processing.

Type of Screening Mesh: Stainless steel with a 3 mm aperture.

Results needed: High throughput, de-dusting at 3 mm.

Main Challenges: To remove all wood particles under 3 mm, without the mesh pegging;

Key Objectives: Grading of the product to remove the particles above 80 micron and delivering at least 100 Kg/Hour of final product;

Main Challenges: The material in its pre-screened state has poor flowability, the particles have an irregular shape that causes pegging and blinding of the mesh. There is also the need to break agglomerates during the screening process.

Results achieved: Virto X-Line achieved all of the core objectives delivering a final product with high efficiency at 99% and met the requested capacity of 100 Kg/h.

Virto is an integrated group of businesses with focused operations on multiple industries worldwide. The group manufactures screening and processing equipment and provides engineering solutions for all industrial applications. The group is privately owned and has offices in Italy, USA and South Africa